An industrial automation controller module includes a main module and an energy storage module (ESM) releasably connected to the main module. The ESM includes a back-up electrical power source such as a battery or a capacitor that is electrically connected to processor circuitry of the main module when the ESM is physically connected to the main module. In case of interruption of operating power to the processor circuitry of the main module, the back-up power source of the ESM supplies back-up power to the main module to allow for completion of an emergency save operation to save data to non-volatile memory in the main module. If the ESM includes a capacitor back-up power source, it is charged by the main module and the capacitor charge is dissipated if the ESM is separated from the main module. In all cases, the ESM can include one or more configuration parameters stored therein that allow the main module to validate (or not) the ESM for the requirements of the main module, with respect to type of back-up power source, product code or model, capacity of back-up power source, and the like. The main module can also initiate periodic testing of the back-up power source of the ESM.
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34. A removable energy storage module comprising:
a housing configured for selectively releasably mating with an associated main module;
a back-up power source supported by the housing;
a first connector operatively connected to said back-up power source and adapted to mate with a second connector of the associated main module for electrical transmission between the associated main module and the energy storage module;
a voltage sensor for sensing a voltage output by the back-up power source;
wherein said back-up power source of said energy storage module selectively supplies back-up power to the associated main module for completing an emergency save operation in which the associated main module saves data to non-volatile memory.
36. A removable energy storage module comprising:
a housing configured for selectively releasably mating with an associated main module;
a back-up power source supported by the housing;
a first connector operatively connected to said back-up power source and adapted to mate with a second connector of the associated main module for electrical transmission between the associated main module and the energy storage module;
a non-volatile memory for saving at least one of: (i) configuration parameters related to said back-up power source; (ii) actual historical operating performance of said back-up power source;
wherein said back-up power source of said energy storage module selectively supplies back-up power to the associated main module for completing an emergency save operation in which the associated main module saves data to non-volatile memory.
27. A removable energy storage module comprising:
a housing configured for selectively releasably mating with an associated main module;
a back-up power source supported by the housing;
a first connector operatively connected to said back-up power source and adapted to mate with a second connector of the associated main module for electrical transmission between the associated main module and the energy storage module;
wherein said back-up power source of said energy storage module selectively supplies back-up power to the associated main module for completing an emergency save operation in which the associated main module saves data to non-volatile memory;
wherein said energy storage module includes one or more configuration parameters related to said back-up power source that enables the main module to validate the energy storage module for requirements of the main module.
47. A removable energy storage module comprising:
a housing configured for selectively releasably mating with an associated main module;
a back-up power source supported by the housing;
a first connector operatively connected to said back-up power source and adapted to mate with a second connector of the associated main module for electrical transmission between the associated main module and the energy storage module;
wherein said back-up power source of said energy storage module selectively supplies back-up power to the associated main module for completing an emergency save operation in which the associated main module saves data to non-volatile memory;
said back-up power source comprising a capacitor that supplies said back-up power, and said energy storage module further comprising means for dissipating power from said capacitor when said energy storage module is disconnected from the associated main module.
38. A method of supplying back-up power to processor circuitry of a main module of an industrial automation controller module for said processor circuitry to complete an emergency save operation, said method comprising:
physically connecting an energy storage module to the main module and electrically connecting a back-up power source and back-up power circuitry of the energy storage module to the processor circuitry of the main module;
receiving a signal from said processor circuitry of said main module into said back-up power circuitry of said energy storage module that back-up power from said back-up power source is required for an emergency save operation;
in response to said signal, supplying back-up power from said back-up power source to said processor circuitry of said main module for said emergency save operation; and
saving at least one of: (i) configuration parameters related to said back-up power source; (ii) actual historical operating performance of said back-up power source, in a non-volatile memory of the energy storage module.
1. An industrial automation controller module comprising:
a main module comprising processor circuitry, volatile memory, and non-volatile memory, wherein said processor circuitry, volatile memory, and non-volatile memory are electrically powered by operating power;
an energy storage module removably connected to the main module and adapted for selective manual separation from the main module, said energy storage module comprising a back-up power source;
wherein said back-up power source of said energy storage module selectively supplies back-up power to said processor circuitry, volatile memory and non-volatile memory of said main module for an emergency save operation in which data from at least one of said processor circuitry and said volatile memory are saved to said non-volatile memory in response to interruption of said operating power;
wherein said energy storage module includes one or more configuration parameters related to said back-up power source that enables the main module to validate the energy storage module for requirements of the main module.
18. An industrial automation controller module comprising:
a main module comprising processor circuitry, volatile memory, and non-volatile memory, wherein said processor circuitry, volatile memory, and non-volatile memory are electrically powered by operating power;
an energy storage module removably connected to the main module and adapted for selective manual separation from the main module, said energy storage module comprising a back-up power source;
wherein said back-up power source of said energy storage module selectively supplies back-up power to said processor circuitry, volatile memory and non-volatile memory of said main module for an emergency save operation in which data from at least one of said processor circuitry and said volatile memory are saved to said non-volatile memory in response to interruption of said operating power, wherein said back-up power source comprises a capacitor that is charged by said operating power from said main module when said energy storage module is physically connected to the main module, and wherein said capacitor supplies said back-up power.
17. An industrial automation controller module comprising:
a main module comprising processor circuitry, volatile memory, and non-volatile memory, wherein said processor circuitry, volatile memory, and non-volatile memory are electrically powered by operating power;
an energy storage module removably connected to the main module and adapted for selective manual separation from the main module, said energy storage module comprising a back-up power source;
wherein said back-up power source of said energy storage module selectively supplies back-up power to said processor circuitry, volatile memory and non-volatile memory of said main module for an emergency save operation in which data from at least one of said processor circuitry and said volatile memory are saved to said non-volatile memory in response to interruption of said operating power;
said main module further comprising a slot adapted to receive said energy storage module, and said main module and said energy storage module comprising respective mechanical features that must be mated for said energy storage module to be physically connected to said main module;
said energy storage module comprising a face plate that at least partially overlies a front wall of said main module, said face plate comprising at least one opening defined therein to provide access to a key switch located on said front wall of said main module, said at least one opening defined in said face plate is conformed and dimensioned such that an associated key installed in said key switch prevents separation of said energy storage module from said main module.
2. The industrial automation controller module as set forth in
3. The industrial automation controller module as set forth in
4. The industrial automation controller module as set forth in
5. The industrial automation controller module as set forth in
6. The industrial automation controller module as set forth in
7. The industrial automation controller module as set forth in
8. The industrial automation controller module as set forth in
9. The industrial automation controller module as set forth in
a step up converter connected to said battery for increasing an output voltage of said battery to a backup voltage level required for said backup power.
10. The industrial automation controller module as set forth in
a step down converter connected to said battery for reducing an output voltage of said battery to a backup voltage level required for said backup power.
11. The industrial automation controller module as set forth in
a test load, wherein said processor circuitry of said main module periodically initiates a test mode in which said test load is connected to said backup power; and,
a voltage sensor for measuring a voltage charge of the battery during said test mode and outputting a test output voltage level.
12. The industrial automation controller module as set forth in
wherein said processor circuitry of said main module computes a reserve power value of said battery based upon changes in the test output voltage level during the test mode; and,
wherein the processor circuitry compares the calculated reserve power value to a known required reserve power value need to complete said emergency save operation and initiates a fault condition if said calculated reserve power value is less than said required reserve power value.
13. The industrial automation controller module as set forth in
14. The industrial automation controller module as set forth in
15. The industrial automation controller module as set forth in
16. The industrial automation controller module as set forth in
19. The industrial automation controller module as set forth in
a step up converter for increasing said operating power to a charging voltage for said capacitor; and,
a step down converter for regulating a backup voltage of said backup power supplied by said capacitor.
20. The industrial automation controller module as set forth in
a test load, wherein said processor circuitry of said main module periodically initiates a test mode in which said test load is connected to said backup power through said step down converter; and,
a voltage sensor for measuring the voltage charge of the capacitor during said test mode and outputting a test output voltage level.
21. The industrial automation controller module as set forth in
wherein said processor circuitry of said main module computes a reserve power value of said capacitor based upon changes in the test output voltage level during the test mode; and,
wherein the processor circuitry compares the calculated reserve power value to a known required reserve power value need to complete said emergency save operation and initiates a fault condition if said calculated reserve power value is less than said required reserve power value.
22. The industrial automation controller module as set forth in
23. The industrial automation controller module as set forth in
24. The industrial automation controller module as set forth in
25. The industrial automation controller module as set forth in
26. The industrial automation controller module as set forth in
means for measuring elapsed time between a completion of said emergency save operation and depletion of back-up power in said capacitor, wherein said means for measuring comprises means for electrically loading said capacitor between completion of said emergency save operation and depletion at a level at least equal to an electrical load on said capacitor during said emergency save operation;
means for saving said measured elapsed time.
28. The removable energy storage module as set forth in
at least one mechanical feature defined by said housing and adapted to mate with a corresponding mechanical feature of the associated main module in order for said housing of said energy storage module to mate with the associated main module.
29. The removable energy storage module as set forth in
30. The removable energy storage module as set forth in
a test load;
means for selectively connecting said back-up power source to said test load to test said back-up power source.
31. The removable energy storage module as set forth in
32. The removable energy storage module as set forth in
33. The removable energy storage module as set forth in
35. The removable energy storage module as set forth in
37. The removable energy storage module as set forth in
39. The method as set forth in
40. The method as set forth in
validating said energy storage module for use with said main module based upon at least one configuration parameter stored in said back-up power circuitry of said energy storage module.
41. The method as set forth in
42. The method as set forth in
43. The method as set forth in
44. The method as set forth in
measuring elapsed time between completion of said emergency save operation and depletion of back-up power from said capacitor;
saving said elapsed time in non-volatile memory.
45. The method as set forth in
46. The method as set forth in
charging said capacitor using operating power supplied from said main module;
depleting said back-up power from said capacitor when said energy storage module is physically and electrically disconnected from said main module.
48. The removable energy storage module as set forth in
a step up converter for input of an operating voltage from said first connector and output of a charging voltage for charging said capacitor; and,
a step down converter for regulating a backup voltage of said backup power supplied by said capacitor.
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This application claims priority from and benefit of the filing date of U.S. provisional patent application Ser. No. 60/987,622 filed Nov. 13, 2007 and entitled Energy Module, Embedded Memory and Display, and said provisional application Ser. No. 60/987,622 is hereby expressly incorporated by reference herein.
Industrial automation controllers are special purpose computers used for the control of industrial machines and/or processes. While executing a stored program, they read inputs from one or more controlled machines/processes and, according to the logic of a contained control program, provide outputs to the same and/or different controlled machine(s)/process(es) based upon the inputs. Industrial controllers must provide “real-time” control (i.e., control in which control outputs are produced predictably and timely in response to given control inputs), and must provide for extremely reliable operation and recovery from faults. In this latter regard, critical data contained in processor registers and other volatile memory (e.g., DRAM, SRAM, SDRAM, etc.) of the controller must be saved or “backed-up” to a non-volatile memory (e.g., flash EEPROM, disk, etc.) in the event of loss of electrical power. Heretofore, this back-up operation has been performed under power supplied by a back-up power source integrated into the controller, typically a replaceable battery (e.g., a 3 volt lithium battery) or a capacitor permanently connected to the controller circuitry and permanently housed within the controller module.
Whether the back-up power source 28 is a battery or a capacitor, these prior back-up power sources 28 have been integrated into the controller module 16 such that a switch from one type of back-up power source to another type by an end-user (e.g., from battery to capacitor) or replacement of the back-up power source is not possible. Such a switch might be required if the controller module 16 is to be moved from one environment (e.g. a factory) to another (e.g., a mine) where batteries are not allowed. Furthermore, battery replacement in these prior controllers requires that the housing of the controller module 16 be opened through an access door or the like to allow the old battery 28 to be disconnected from and the new battery connected to the controller module 16. This prior battery replacement operation is sometimes difficult or inconvenient or excessively time-consuming in an industrial environment, can be unsafe due to potential exposure to high-voltage electronics, and can require the controller module to be powered down during the replacement process. It is important to reduce the time required to replace a back-up power source to account for the possibility of a power failure occurring during the replacement operation and to allow for replacement of a controller back-up power source during controller operation. Also, if a back-up power source replacement operation is too difficult or inconvenient, it is possible that an end-user will not periodically replace the back-up power source as required.
In light of the foregoing, it has been deemed desirable to provide an energy storage module for an industrial automation controller, and an industrial automation controller module including such an energy storage module, wherein the energy storage module includes any desired suitable back-up energy source and wherein the energy storage module is specially adapted to ensure safe and reliable operation of itself and the industrial automation controller module to which it is mated.
In accordance with one aspect of the present development, an industrial automation controller module includes a main module comprising processor circuitry, volatile memory, and non-volatile memory, wherein the processor circuitry, volatile memory, and non-volatile memory are electrically powered by operating power. The controller module further includes an energy storage module removably connected to the main module and adapted for selective manual separation from the main module. The energy storage module includes a back-up power source. The back-up power source of the energy storage module selectively supplies back-up power to the processor circuitry, volatile memory and non-volatile memory of the main module for an emergency save operation in which data from at least one of the processor circuitry and the volatile memory are saved to the non-volatile memory in response to interruption of the operating power.
In accordance with another aspect of the present invention, a removable energy storage module includes a housing configured for selectively releasably mating with an associated main module. A back-up power source is supported by the housing. A first connector is operatively connected to the back-up power source and is adapted to mate with a second connector of the associated main module for electrical transmission between the associated main module and the energy storage module. The back-up power source of the energy storage module selectively supplies back-up power to the associated main module for completing an emergency save operation in which the associated main module saves data to non-volatile memory.
In accordance with another aspect of the present invention, a method of supplying back-up power to processor circuitry of a main module of an industrial automation controller module for the processor circuitry to complete an emergency save operation includes physically connecting an energy storage module to the main module and electrically connecting a back-up power source and back-up power circuitry of the energy storage module to the processor circuitry of the main module. The method further includes receiving a signal from the processor circuitry of the main module into the back-up power circuitry of the energy storage module that back-up power from the back-up power source is required for an emergency save operation and, in response to the signal, supplying back-up power from the back-up power source to the processor circuitry of the main module for the emergency save operation.
A controller module 116 formed in accordance with the present development is shown in
In place of the conventional back-up electrical power source 28 used in the controller module 16 of
Referring to all of
The main housing 140 of the controller module 116 typically comprises multiple pieces and includes or defines a slot or other opening 150 adapted to receive and retain the ESM as shown in
Referring specifically to
When the ESM is fully installed in the slot 150 as shown in
The ESM preferably comprises a latch 166a connected to its face plate 164 and adapted to mate with a catch 166b defined by the main housing 140. When the ESM is mated with the main housing 140, the latch 166a mates with the catch 166b so that the ESM is captured to the main module housing 140 by the latch 166a. The latch 166a is selectively manually releasably to allow separation of the ESM from the main module housing 140, e.g., the latch is defined as a one-piece resilient polymeric structure with the face plate 164 and/or includes a separate biasing spring or the like.
The ESM face plate 164 is conformed and dimensioned so as not to obstruct certain features/structures of the main module MM. For example, the main module MM includes a USB data port 180a located in the front wall 140a of the main housing 140, and the face plate 164 includes a corresponding opening 180b to accommodate same. Similarly, the main module MM comprises a key switch 182a adapted to receive a key to control operation of overall control module 116 (on/off/test/program/etc.). The ESM face plate 164 includes a corresponding key switch opening 182b adapted to accommodate the key switch 182a to allow use of the key switch 182a when the ESM is operatively installed. Furthermore, the key switch opening 182b is conformed and dimensioned to lie closely adjacent or completely surround the key switch 182a such that any key in the key switch 182a must be removed from the key switch before the ESM can be separated from the main module MM, i.e., any key in the key switch will interfere with the face plate 164 of the ESM if removal of the ESM is attempted without first removing the key from the key switch 182a (which helps to ensure that the key will not be turned to change the state of the key switch while the ESM is separated from the main module MM).
More particularly, ESM input electrical power Vcc (e.g., 4.75 to 5.25 volts) is supplied to the ESM circuit board 170 sourced from the backplane operating power. The ESM input voltage Vcc is input to a step up converter 202 that increases the voltage to a charging voltage that is output to the capacitor 172C for charging the capacitor. In one example, the capacitor is rated to 400 volts and the step up converter outputs 350 volts for charging the capacitor 172C. Likewise, the capacitor 172C stores a back-up voltage that is output through a step down converter 204 that supplies the back-up operating voltage BKUPV (e.g., 4 to 5 volts DC) to the controller module 116 to complete the emergency save operation. In one example, the step up converter and step down converter can be provided by respective flyback transformers.
In one embodiment, the ESM comprises a test load 210 (e.g., a resistor) and switch means 212 controlled by the processor 132 of the main circuit board 126 by a signal LOAD_BKUPV for selectively powering the test load 210 from the step down converter 204 to measure the reserve power of the capacitor 172C during a test mode. A voltage sensor 216 monitors the voltage of the capacitor 172C during the test mode, and outputs a test output voltage level ESV to the main circuit board 126. The processor circuitry 132 calculates the reserve power of the capacitor 172C based upon the changes in the test output voltage level ESV during the test mode, which will last only a short time, e.g., a fraction of a second. In an alternative method, starting from the regulated capacitor full voltage level, the test load 210 is connected to the capacitor until the capacitor voltage level decreases to a threshold voltage, and the elapsed time for this known voltage drop is used to calculate the reserve power of the fully charged capacitor. The processor circuitry 132 will compare the calculated reserve power of the capacitor 172C to the known required reserve power required for an emergency save operation, which will vary depending upon the processor circuitry 132, and the type and size of the volatile memory 130 and non-volatile memory 134, and the size of the program being run by the processor circuitry 132. If the calculated reserve power is not at least equal to the known required reserve power to complete the emergency save operation, the processor circuitry 132 will determine that the capacitor 172C of the ESM lacks sufficient reserve capacity to perform the emergency save effectively and will initiate a fault condition which can lead to an audible and/or visual (e.g., LED or the like) output from the control module 116 to indicate such fault condition, in which case the ESM can be replaced. If operating power to the main module MM is interrupted during the test mode, the processor circuitry immediately exits the test mode and initiates the emergency save operation. The test load 210 is also used for regulation of the output BKUPV of the step down converter 204, which helps to improve the accuracy of the reserve power calculated during test mode.
The capacitor ESM (ESM1) preferably further comprises a real-time clock RTC that interfaces with the main circuit board 126 including the processor circuitry 132. In the illustrated example, the real-time clock RTC is powered by a separate capacitor C2, e.g., a supercapacitor that can power the real-time clock for a minimum of five days. The real-time clock RTC comprises non-volatile memory such as an EEPROM that is used to store configuration parameters of the ESM as described further below. The real-time clock is also used to validate the overall capacity of the ESM capacitor 172C after completion of the emergency save operation, as described further below.
For safety, the capacitor based ESM (ESM1) is configured such that upon separation of the ESM from the main module MM, the capacitor 172C will automatically discharge itself, e.g., through the test load 210 as controlled by switch 212. In one embodiment, separation of the capacitor based ESM (ESM1) from the main module MM will cause the ESM to enter the above-described test mode, which will cause the stored capacitive energy to be discharged in less than one minute.
ESM input electrical power Vcc (e.g., 4.75 to 5.25 volts) is supplied to the ESM circuit board 170 sourced from the backplane operating power. If the battery 172B is rechargeable, the ESM input voltage Vcc is used to charge the battery 172B as controlled by the processor circuitry 132, optionally by boosting the ESM input voltage Vcc through a step up converter 202 (or step down of the ESM input voltage Vcc through a step down converter) if required. The battery 172B stores a back-up voltage (e.g., 3 volts) that is output to the step up converter 202 (or a step down converter 204 (
As with the capacitor ESM (ESM1) the illustrated battery ESM (ESM2) comprises a test load 210 (e.g., a resistor) and switch means 212 controlled by the processor 132 of the main circuit board 126 through a signal LOAD_BKUPV for selectively powering the test load 210 from the boost converter 202 to measure the reserve power of the battery 172B during a test mode. A voltage sensor 216 monitors the voltage of the battery 172B during the test mode, and outputs a test output voltage level ESV to the main circuit board 126. The processor circuitry 132 calculates the reserve power of the battery 172B based upon the changes in the test output voltage level ESV during the test mode, which will last only a short time, e.g., less than one second. The processor circuitry 132 will compare the calculated reserve power to its known required reserve power for an emergency save operation, which will vary depending upon the processor circuitry 132, and the type and size of the volatile memory 130 and non-volatile memory 134, and the size of the program being run by the processor circuitry 132. If the calculated reserve power is not at least equal to the known required reserve power to complete the emergency save operation, the processor circuitry 132 will determine that the battery 172B of the ESM lacks sufficient reserve capacity to perform the emergency save effectively and will initiate a fault condition which can lead to an audible and/or visual (e.g., LED or the like) output from the control module 116 to indicate such fault condition, in which case the ESM can be replaced. If the operational power supplied from the backplane 22 to the main module MM fails during the test mode, the processor circuitry immediately terminates the test mode and initiates the emergency save operation.
The battery ESM (ESM2) preferably further also comprises a real-time clock RTC that interfaces with the main circuit board 126 including the processor circuitry 132. As shown, the real-time clock RTC is powered by the ESM battery 172B, but a separate battery or capacitor can be provided to power the real-time clock. The real-time clock RTC comprises non-volatile memory such as an EEPROM that is used to store configuration parameters of the ESM as described further below.
To preserve battery life, the battery based ESM (ESM2) is configured such that upon separation of the ESM from the main module MM, the battery is isolated from loads on the ESM circuit board 170 except the real-time clock RTC, to extend the battery life a maximum possible extent.
Both the capacitor and battery ESM (ESM1,ESM2) include non-volatile memory such as the EEPROM provided as part of the real-time clock RTC. This non-volatile memory is programmed to include configuration parameters that identify the type of back-up power source 172 in the ESM (capacitor, battery, etc.), the nominal or rated capacity of the back-up power source 172 (e.g., 220 uF, 350V capacitor or 3 volt battery, etc.). In one embodiment, the non-volatile memory of the ESM includes a serial number or like unique identifier for the ESM, so that same can be logged as part of any emergency save operation or as otherwise required. Certain of these configuration parameters can also be set using a jumper device on the ESM circuit board 170, e.g., to identify the ESM as either battery or capacitor based.
Also, during operation of the ESM, the non-volatile memory can be updated to include results from the above-described test mode with respect to the reserve power capacity of the back-up power source 172. Similarly, in the case of the capacitor based ESM (ESM1), the duration of the emergency save operation is logged by the real-time clock RTC, and the capacitor 172C is further operated with a load at least equal to that of the emergency save operation to supply back-up power (e.g., through the test load 210) after completion of the emergency save operation in order to measure any residual reserve power capacity until depletion of the capacitor, and this information is also stored to the real-time clock EEPROM or other non-volatile memory for later use in assessing or validating the maximum reserve power capacity of the capacitor relative to the power requirements of the emergency save operation. For example, upon the next power up of the controller module 116, the main module processor circuitry 132 can calculate the ratio of the duration of the emergency save operation to the total operation time of the ESM (the duration of the emergency save operation+the duration from completion of the emergency save operation to depletion of the capacitor) to validate the ESM for a the back-up power requirements (program size, memory size, etc.) of the particular main module. If the ratio is above a threshold, the ESM will be deemed to have insufficient back-up energy capacity for future use with the particular main module, i.e., the ESM will be deemed to have insufficient excess energy capacity.
The processor circuitry 132 of each main module MM can be preprogrammed to accept an ESM with only certain configuration parameters stored in the non-volatile memory of the real-time clock RTC or elsewhere. For example, if the main module MM is to be used in a mining application, the processor circuitry will be programmed to accept only a capacitor based ESM (ESM1) and to initiate a fault condition with visual and/or audible warnings if a battery based ESM (ESM2) is operatively installed in the slot 150. Similarly, the processor circuitry 132 can be programmed to accept an ESM only if the back-up power source 172 of the ESM is rated to sufficient reserve power capacity to complete an emergency save operation for the particular processor circuitry 132, type/size volatile memory, size of the program being executed by the processor circuitry and the like. Here, again, if an ESM with insufficient reserve power capacity is installed in the slot 150 of the main module MM, a fault condition will be indicated.
The back-up power source 172 is described herein as being a capacitor 172C or a battery 172B, but those of ordinary skill in the art will recognize that other back-up power sources can be used without departing from the overall scope and intent of the present development.
It is preferred that the ESM be configured to remain inactive when first installed in the slot 150 of the main module, until such time that the ESM input power Vcc is supplied to the ESM. This will help to ensure that the ESM has been correctly installed in a main module MM prior to operation of the ESM.
In an alternative embodiment, the capacitor based ESM (ESM1), in addition or as an alternative to the above-described test mode, includes a temperature sensor for monitoring the temperature in the ESM space adjacent the capacitor 172C. For controller modules that typically run continuously, the capacity/lifetime of the capacitor 172C of the ESM can be predicted by monitoring the temperature inside the controller module 116. Temperature is a dominant factor to for determining capacitor degradation (adjustments can be made for any off time of the controller module 116). For example, a 220 uF capacitor at 350V stores 13.475 joules (J) of energy. Allowing for a 20% capacitor tolerance drops the nominal energy capacity to 10.78 J. The step down converter 204 is about 82-83% efficient, which lowers the capacity to 8.84 J. Capacitor life is rated at 12,000 hours at 105 degrees Celsius (C). Operation at every 10 C below 105 C represents an approximate doubling of capacitor life, with a capacitor lifetime equivalent to a 20% capacitance loss. Continuous 85 C operation moves the rated lifetime to 48,000 hours with a corresponding drop in capacity to 7.072 J. 96,000 hours operation at continuous 85C temperature drops capacity to 5.66 J. The ending capacitor discharge voltage of 30V loses 0.1 J., dropping available capacity to 5.56 J.
It should also be noted that some or all of the data exchanged between the ESM circuit board 170 and the main circuit board 126 can be encrypted. This can minimize the likelihood of unauthorized access to data in the ESM, and can also help to ensure that unauthorized ESM modules cannot be used in order to improve safety and performance.
The development has been described with reference to preferred embodiments. Those of ordinary skill in the art will recognize that modifications and alterations to the preferred embodiments are possible. The disclosed preferred embodiments are not intended to limit the scope of the following claims, which are to be construed as broadly as possible, whether literally or according to the doctrine of equivalents.
Bodmann, Douglas R., Schultz, Ronald E., Kay, James J., Terdan, Dale R., Killian, Daniel E.
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